BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a die, a method of manufacturing a stepped metal
pipe or tube, and a stepped metal pipe or tube. The invention more specifically relates
to a die for use in an extrusion process for reducing the diameter of a metal pipe
or tube, a method of manufacturing a stepped metal pipe or tube using the die, and
a stepped metal pipe or tube.
2. Description of the Related Art
[0002] Among automobile parts such as a shaft, some parts have a stepped shape of varying
diameter in the axial direction (hereinafter referred to as "stepped parts") as shown
in Fig. 1. Such a stepped part is manufactured by subjecting a solid material to an
extrusion process and reducing its diameter. Referring to Figs. 2A to 2D, a columnar
solid material is cut into billets 1 having a prescribed length (Fig. 2A). Then, a
billet 1 is placed in the vertical direction on a die 2 for extrusion, and a press
3 is placed on the upper end of the billet 1 (Fig. 2B). The billet 1 is then pushed
into a through hole 21 of the die 2 and the lower end of the billet 1 is forced out
from the lower surface of the die 2 (Fig. 2C). The lower end of the billet 1 is extruded
to protrude a prescribed distance from the lower surface of the die 2, and then the
billet 1 is pushed out from the die 2 using a push-out jig 4 (Fig. 2D). By these processes,
the billet 1 is formed into a stepped part.
[0003] As shown in Fig. 2B, the through hole 21 of the die 2 has an inside surface including
a bell portion 211, an approach portion 212, a bearing portion 213, and a relief portion
214 formed in a continuous manner. The bell portion 211 serves to guide the billet
1 toward the approach portion 212. Compressing force in the radial direction is exerted
for the first time on the billet 1 by the approach portion 212, and the diameter of
the billet is reduced. The die half angle R1 of the approach portion 212 is usually
fixed.
[0004] In recent years, in order to manufacture more lightweight automobiles, stepped metal
pipes or tubes produced by extruding hollow metal pipes or tubes are coming to be
used as stepped parts.
[0005] However, when a stepped metal pipe or tube is produced by a conventional extrusion
process using the die 2, the cylindrical portion with a reduced diameter is bent as
shown in Fig. 3. A stepped metal pipe or tube attached to an automobile usually rotates
in the axial direction. A bent stepped metal pipe or tube is not preferable because
it vibrations during rotation.
[0006] Document
JP-A-51 123 761 discloses a method of manufacturing a stepped metal pipe or tube by pushing metal
pipe or tube into a die in an axial direction, said die having a through hole for
use in an extrusion process to reduce the diameter of the metal pipe or tube.
[0007] Japanese Patent Laid-Open No.
2002-11518 discloses a die for use in a drawing process. Unlike the extrusion process carried
out without fixing the tip end of the material, the tip end of the material is chucked
while it is pulled out in the drawing process, and therefore it is not easy for bending
to occur. Therefore, the die for drawing and the die for extrusion have different
shapes.
SUMMARY OF THE INVENTION
[0008] It is an object of the invention to provide a die that can prevent the bending deformation
of a stepped metal pipe or tube manufactured by extruding a metal pipe or tube and
a stepped metal pipe or tube manufactured using such a die from occurring.
[0009] The inventors subjected a metal pipe or tube (hereinafter as "metal pipe") 10 to
an extrusion process by pushing it into a conventional die 2 as shown in Fig. 4 in
order to find the cause of bending of a stepped metal pipe. The inventors found that
the reduced outside diameter DB of the metal pipe 10 becomes smaller than the diameter
D11 of the through hole 21 in the bearing portion 213 of the die 2. Such deformation
will hereinafter be referred to as "undershooting deformation."
[0010] When the metal pipe 10 is subjected to an extrusion process using the die 2, the
part of the metal pipe 10 passing through the approach portion 212 undergoes bending
deformation in the radial direction by the inside surface of the approach portion
212 and has its diameter reduced. The part let out of the approach portion 212 and
existing in the bearing portion 213 undergoes no bending deformation by the inside
surface of the bearing portion 213, but the part, in the process of passing through
the approach portion 212, is affected by the bending deformation at the moment undergoes
bending deformation by the inside surface of the approach portion 212. This causes
undershooting deformation.
[0011] When lubrication is not uniform or the metal pipe 10 is slightly slanted with respect
to the die 2 during the extrusion process, the metal pipe 10 has its diameter reduced
unevenly with respect to the axis of the pipe 10. The reduced outside diameter DB
of the metal pipe 10 becomes smaller than the diameter D11 at the bearing portion
213 because of the undershooting deformation, and therefore the metal pipe 10 is not
restrained by the bearing portion 213. The non-uniform deformation portion in the
metal pipe 10 caused by the working by the approach portion 212 cannot be straightened
by the bearing portion 213. Consequently, the extruded metal pipe 10 has a bent portion.
[0012] The inventors drew a conclusion that the bending of the stepped metal pipe can be
reduced if the undershooting deformation of the metal pipe is prevented from occurring
at the bearing portion 213. This is because the metal pipe 10 is restrained by the
bearing portion 213 if there is no undershooting deformation of the metal pipe at
the bearing portion 213.
[0013] In order to prevent undershooting deformation of the metal pipe from occurring at
the bearing portion 213, it is sufficient to allow the undershooting deformation to
start and to be completed before the outside diameter of the metal pipe 10 is reduced
to D11 by the extrusion process.
[0014] The inventors therefore subjected metal pipes having various outside diameters DA
and thicknesses to an extrusion process using a die 2 and investigated undershooting
deformation of the metal pipes 10. It was newly found based on the results that when
the working ratio of the outside diameter is not more than 30% in an extrusion process,
the undershooting deformation of the metal pipe 10 is less than 3% of the diameter
D11 of the bearing portion 213. Note that the undershooting deformation did not depend
on the outside diameter DA and the thickness of the metal pipe 10 before the extrusion
process.
[0015] The inventors have made the following invention based on the studies and results
of examination described above.
[0016] A die according to the invention has a through hole for use in an extrusion process
to reduce the diameter of a metal pipe or tube. The through hole has an inside surface
including a bell portion, an approach portion, and a bearing portion from the entrance
side formed in a continuous manner. The diameter of the through hole at the bell portion
gradually decreases from the entrance side of the bell portion to the exit side of
the bell portion, and the diameter of the through hole at the approach portion is
D1 on the entrance side of the approach portion and D2 on the exit side of the approach
portion and gradually decreases from the entrance side of the approach portion to
the exit side to satisfy Equation (1):
[0017] The die half angle of the inside surface where the diameter D3 is D2/0.97 is not
less than the die half angle of the inside surface nearer to the exit side of the
approach portion than the inside surface where the diameter is D3, and the axial length
LR from the inside surface where the diameter is D3 to the inside surface where the
diameter is D2 satisfies Equation (2):
[0018] The diameter of the through hole in the bearing portion is fixed at D2, and the length
is LB and satisfies Equation (3):
[0019] In the die according to the invention, the die half angle of an inside surface where
the diameter of the through hole at the approach portion is D3 is not less than the
die half angle of an inside surface more on the exit side than the inside surface
where the diameter is D3, and the length LR satisfies Equation (2). Therefore, the
die half angle is small on the inside surface more on the exit side than the inside
surface where the diameter is D3, and the metal pipe or tube between the inside surface
where the diameter is D3 and the exit of the approach portion undergoes almost no
bending deformation. Consequently, the metal pipe is allowed to undergo undershooting
deformation when the pipe passes through the region from the inside surface where
the diameter is D3 to the exit of the approach portion. As can be understood from
the results of examination described above, the undershooting deformation is less
than 3% when the working ratio of the outside diameter is not more than 30%, and therefore
the undershooting deformation of the metal pipe or tube occurring from the inside
surface where the diameter is D3 ends before the metal pipe or tube reaches the exit
of the approach portion. Stated differently, no undershooting deformation occurs after
the metal pipe or tube passes the approach portion. Consequently, the metal pipe or
tube is restrained by the bearing portion.
[0020] The length of the bearing portion satisfies Equation (3) and therefore non-uniform
deformation portion of the metal pipe or tube caused by the working by the approach
portion can be straightened. In this way, the bending of the metal pipe or tube can
be prevented.
[0021] A method of manufacturing a stepped metal pipe or tube according to the invention
includes pushing a metal pipe or tube into a die in the axial direction, extruding
an end of the pushed metal pipe or tube to protrude a prescribed length from the exit
side of the die, thereby making the metal pipe or tube into a stepped metal pipe or
tube, and stopping extruding and pushing back the stepped metal pipe or tube in the
direction opposite to the direction of pushing the metal pipe or tube. The die has
a through hole for use in an extrusion process to reduce the diameter of a metal pipe
or tube. The through hole has an inside surface including a bell portion, an approach
portion, and a bearing portion from the entrance side formed in a continuous manner.
The diameter of the through hole at the bell portion gradually decreases from the
entrance side of the bell portion to the exit side of the bell portion, the diameter
of the through hole at the approach portion is D1 on the entrance side of the approach
portion and D2 on the exit side of the approach portion and gradually decreases from
the entrance side to the exit side to satisfy Equation (1), the die half angle of
an inside surface where the diameter D3 is D2/0.97 is not less than the die half angle
of an inside surface more on the exit side of the approach portion than the inside
surface where the diameter is D3, the axial length LR from the inside surface where
the diameter is D3 to the inside surface where the diameter is D2 satisfies Equation
(2), the diameter of the through hole in the bearing portion is fixed at D2, and the
length is LB and satisfies Equation (3).
[0022] The metal pipe or tube is preferably manufactured by a Mannesmann process.
[0023] According to the invention there is provided a stepped metal pipe or tube manufactured
by the method according to claim 2 or 3 including a first hollow cylindrical portion,
a taper portion, and a second hollow cylindrical portion formed in a continuous manner,
the outside diameter of the first hollow cylindrical portion is DA, the outside diameter
of the second hollow cylindrical portion is DB that is smaller than DA, the outside
diameter of the taper portion gradually decreases from the first hollow cylindrical
portion to the second hollow cylindrical portion as the value of the outer diameter
decreases from DA to DB, and the axial distance LE from the surface where the outside
diameter DC is DB/0.97 to the surface where the outside diameter is DB satisfies Equation
(4):
BRIEF DESCRIPTION OF THE DRAWINGS
[0024]
Fig. 1 is an external view of a conventional stepped part:
Figs. 2A to 2D are views of the first to the forth steps in an extrusion process using
a conventional die:
Fig. 3 is an external view of a stepped part having a bent end portion;
Fig. 4 is a schematic view for illustrating the cause of the bending of a stepped
metal pipe during an extrusion process;
Fig. 5 is a sectional view of a die according to an embodiment of the invention taken
in the vertical direction;
Fig. 6 is a schematic view for illustrating the state of a metal pipe when it is processed
by extrusion using the die as shown in Fig. 5;
Fig. 7 is a sectional view of another example of the die according to the embodiment
of the invention;
Figs. 8A to 8C are views of the first to the third steps in an extrusion process using
the die shown in Fig. 5;
Fig. 9 is a sectional view of the die used in the example;
Fig. 10 is a schematic view for illustrating a method of measuring bending in a stepped
metal pipe; and
Fig. 11 is a graph showing the results of measuring the outside diameter in various
axial positions of a stepped metal pipe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Now, an embodiment of the invention will be described in detail in conjunction with
the accompanying drawings, in which the same or corresponding portions are denoted
by the same reference numerals and their descriptions are also the same as or similar
to each other.
1. Die
[0026] Referring to Fig. 5, a die 30 according to the embodiment has a through hole 31.
The geometry of the through hole 31 has an inside surface that starts from a bell
portion 311 on the entrance side followed by an approach portion 312, a bearing portion
313, and a relief portion 314 in a continuous manner.
[0027] Now, the geometry of the through hole 31 will be detailed.
1. 1. Bell portion
[0028] The bell portion 311 serves to guide a metal pipe 10 into the through hole 31. The
bell portion 311 does not exert compressing force on the metal pipe 10, and therefore
the metal pipe 10 does not have its diameter reduced by the bell portion 311. The
diameter of the through hole 31 at the bell portion 311 decreases gradually from the
entrance side to the exit side.
1. 2. Approach portion
[0029] The approach portion 312 serves to reduce the diameter of the metal pipe 10. In short,
the metal pipe 10 receives compressing force exerted in the radial direction for the
first time on the approach portion 312 and has its diameter reduced. The diameter
of the through hole 31 at the approach portion 312 gradually decreases from the entrance
side to the exit side. When the diameter of the entrance of the approach portion 312
is D1, and the diameter of its exit is D2, D1 and D2 satisfy the following Equation
(1):
[0030] The lower limit in Equation (1) is 0.7 because the advantage of the invention is
particularly effectively obtained when the working ratio of the outside diameter of
the metal pipe 10 is not more than 30%. Herein, the working ratio of the outside diameter
is defined by the following Equation (A):
where DA represents the outside diameter of the metal pipe 10 before extrusion, and
DB represents the outside diameter of the metal pipe 10 having a reduced diameter
after the extrusion. Note that even for a value smaller than the lower limit in Equation
(1), the advantage of the invention can be obtained to some extent. The upper limit
is 0.97 in Equation (1) because the advantage of the invention cannot be obtained
effectively when the working ratio of the outside diameter is less than 3%.
[0031] At the approach portion 312, the die half angle R1 of the inside surface S
D3 where the diameter D3=D2/0.97 is not less than the die half angle R2 of the inside
surface S
D3-D2 more on the exit side than the inside surface S
D3.
[0032] The axial length LR from the inside surface S
D3 to the inside surface S
D2 where the diameter is D2 satisfies the following Equation (2):
[0033] As the length LR becomes longer with respect to the diameter difference D3-D2, the
die half angle R2 on the inside surface S
D3-D2 becomes smaller.
[0034] In order to prevent the metal pipe 10 from undergoing undershooting deformation at
the bearing portion 313, it is sufficient that undershooting deformation is intentionally
caused while the pipe passes through the approach portion 312, and the undershooting
deformation is finished before the pipe reaches the exit of the approach portion 312.
When the die half angle R1 of the inside surface S
D3 where D3 is D2/0.97 is not less than the die half angle R2 of the inside surface
S
D3-D2, and the length LR satisfies Equation (2), the die half angle R2 is very small. Therefore,
as shown in Fig. 6, the metal pipe 10 does not contact the die 30 on the entrance
side of the inside surface S
D3-D2 (see the region 50 in Fig. 6), and undergoes undershooting deformation at the inside
surface S
D3-D2.
[0035] As described above, when the working ratio of the outside diameter of the metal pipe
10 is not more than 30%, the undershooting deformation is less than 3% of the diameter
D2. Therefore, when undershooting deformation is caused from the inside surface S
D3, the outside diameter of the metal pipe 10 after the undershooting deformation is
more than D2.
[0036] The metal pipe 10 after the undershooting deformation again contacts the approach
portion 312 and has its diameter slightly reduced before it reaches the entrance of
the bearing portion 313 (see the region 51 in Fig. 6). However, since the working
ratio of the outside diameter is low and the die half angle R2 of the inside surface
S
D3-D2 is small, compressing force exerted on the metal pipe 10 in the region is very small.
Therefore, no undershooting deformation is caused by the bearing portion 313.
[0037] Note that when the length LR is not less than the lower limit in Equation (2), the
above described advantage can effectively be provided. The upper limit in Equation
(2) is 115 because with the length LR longer than this value the entire length of
the die 30 becomes too long. This pushes up the manufacturing cost for the die and
the installation cost for the press. When the upper limit in Equation (2) is more
than 115, the advantage of the invention can effectively be provided.
[0038] In Fig. 5, the approach portion 312 has a two section straight geometry along the
inside surface from the entrance to the inside surface S
D3, then to the inside surface S
D3-D2, but it may have a different geometry. For example, as shown in Fig. 7, the approach
portion 312 may be curved. In short, it is sufficient that the die has its diameter
gradually reduced from the entrance side to the exit side of the approach portion
312, the die half angle R1 is not less than the die half angle R2, and the length
LR satisfies Equation (2). Note that when the approach portion 312 is curved as shown
in Fig. 7, the die half angle refers to the angle formed between a tangent line to
a prescribed inside surface on the approach portion 312 and the central axis of the
through hole 31.
1. 3. Bearing portion
[0039] The bearing portion 313 serves to restrain the extruded metal pipe 10 and improve
the straightness of the metal pipe 10. The length LB of the bearing portion 313 satisfies
the following Equation (3):
[0040] The bearing portion length LB is in proportion to the diameter D2. As the bearing
portion length LB is longer, non-uniform deformation portion of the metal pipe 10
caused by the working by the approach portion 312 can be more straightened. In this
way, the metal pipe 10 can be prevented from bending. When the bearing portion length
LB satisfies Equation (3), the above-described advantage can effectively be obtained
and the straightness of the metal pipe 10 is improved. Note that the upper limit in
Equation (3) is 10 because with the bearing portion length LB larger than the value
the die 30 becomes too long. This pushes up the manufacturing cost for the die. If
the upper limit is higher than the value in Equation (3), the above-described advantage
can effectively be obtained.
2. Manufacturing Method
[0041] A method of manufacturing a stepped metal pipe according to the embodiment will be
described. Molten steel is produced either by a blast furnace or by an electric furnace.
The produced molten steel is then refined by a conventional process. The refined molten
steel is processed by a continuous casting method or by an ingot casting method and
formed into, for example, a slab, a bloom, a billet or an ingot.
[0042] The slab, bloom or ingot is processed by hot working and made into a billet. The
hot working process can be either a hot rolling process or a hot forging process.
[0043] In the following process, the billet is processed into a metal pipe by a Mannesmann
process. In the process, the billet is pierced by a piercing mill and made into a
hollow shell (piercing process). The hollow shell is elongated in the axial direction
by a mandrel mill (elongating process). After the elongating process, the outside
diameter of the hollow shell is sized to a specified value by a sizing mill (sizing
process).
[0044] The metal pipe manufactured by the Mannesmann process is subjected to an extrusion
process to manufacture a stepped metal pipe. With reference to Figs. 8A to 8C, a prescribed
length of the metal pipe 10 is provided between a press 3 that presses the metal pipe
10 in the vertical direction and a die 30 (Fig. 8A). Then, the upper end of the metal
pipe 10 is pressed in the vertical direction by the press 3 and the lower end of the
metal pipe 10 is pushed into the die 30. The lower end of the metal pipe 10 is extruded
to protrude a prescribed distance from the lower end of the die 30, and then the extrusion
process by the press 3 is stopped (Fig. 8B). At this time, the metal pipe 10 becomes
a stepped metal pipe 11. Then, the metal pipe 11 is pushed back by a push-out jig
4 in the direction opposite to the direction in which the stepped metal pipe 11 is
extruded (Fig. 8C).
[0045] The stepped metal pipe 11 manufactured by this extrusion process includes a first
hollow cylindrical portion 101, a taper portion 102, and a second hollow cylindrical
portion 103 formed in a continuous manner. The outside diameter of the first hollow
cylindrical portion 101 is DA, and the outside diameter DB of the second hollow cylindrical
portion 103 is smaller than DA.
[0046] The outside diameter of the taper portion 102 gradually decreases from the first
hollow cylindrical portion 101 to the second hollow cylindrical portion 103. In other
words, the diameter gradually decreases from DA to DB. Furthermore, the axial length
LE from the surface where the outside diameter is DC is DB/0.97 to the surface where
the outside diameter is DB satisfies the following Equation (4):
[0047] The above-described method of manufacturing a metal pipe according to the Mannesmann
process includes the processes of piercing, rolling, and sizing, while the method
may include other processes. For example, the process of straightening the bent portion
of the metal pipe in the axial direction or the process of improving the roundness
of the metal pipe may be carried out after the sizing process and before manufacturing
the stepped metal pipe. The straightening process is carried out by a device such
as a straightener. In order to adjust mechanical characteristics of the metal pipe
such as strength and ductility, thermal treatment may be carried out between the sizing
process and the straightening process.
After the straightening process, the metal pipe may be subjected to a swaging process
in order to adjust the inside diameter of the end of the metal pipe (swaging process).
For example, the end of the metal pipe may be pushed into a die for extrusion and
have its inside diameter adjusted.
In this method, the process of manufacturing the stepped pipe is carried out after
the swaging process.
[0048] The stepped metal pipe manufactured by the processes in Figs. 8A to 8C may be subjected
to thermal treatment in order to eliminate possible redundant strain or residual stress
on the stepped metal pipe caused by the working. The thermal treatment may also be
carried out for the purpose of adjusting mechanical characteristics of the stepped
metal pipe such as the strength and ductility.
[0049] By the above-described manufacturing method, a seamless pipe is used as a metal pipe,
but a stepped metal pipe may be manufactured using a welded steel pipe as a metal
pipe.
[0050] There is no restriction on the material of the die 30. For example, the material
can be either high-speed steel or cemented carbide. There is no restriction on the
roughness of the inside surface of the through hole 31. The inside surface may be
a polished surface or a mirror finished surface. The inside surface of the through
hole 31 may be coated.
[0051] Although the die half angle of the bell portion 311 and the die half angle R1 of
the approach portion 312 are different in Fig. 5, these angles may be the same.
Example 1
[0052] Metal pipes and dies sized as in Table 1 were used to carry out extrusion tests,
and the bending of the metal pipes after the extrusion was examined.
Table 1
No. |
die |
metal pipe |
bending S (mm) |
evaluation |
metal pipe |
D1 (mm) |
D2 (mm) |
D3 (mm) |
R1 (°) |
R2 (°) |
LR (mm) |
LB (mm) |
F1 |
F2 |
outside diameter DA (mm) |
thickness (mm) |
outside diameter DB (mm) |
outside diameters DC (mm) |
(LE mm) |
Exp. (4) |
1 |
50 |
34 |
35.05 |
10 |
6.0 |
10 |
40.0 |
*19.0 |
1.18 |
40 |
6 |
33.6 |
0.7 |
× |
- |
- |
- |
2 |
50 |
34 |
36.05 |
10 |
4.0 |
15 |
40.0 |
28.5 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
13.8 |
26.2 |
3 |
50 |
34 |
35.05 |
10 |
3.0 |
20 |
40.0 |
38.0 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
18.8 |
35.8 |
4 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
27.1 |
51.6 |
5 |
50 |
34 |
35.05 |
10 |
1.2 |
50 |
40.0 |
95.1 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
47.2 |
89.8 |
6 |
50 |
34 |
35.05 |
10 |
0.9 |
70 |
40.0 |
133.1 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
- |
- |
- |
7 |
50 |
34 |
35.05 |
10 |
10.0 |
3 |
40.0 |
*11.4 |
1.18 |
40 |
6 |
33.5 |
0.8 |
× |
34.5 |
9.9 |
*19.1 |
8 |
50 |
34 |
35.05 |
25 |
6.0 |
10 |
40.0 |
*19.0 |
1.18 |
40 |
6 |
33.5 |
0.8 |
× |
- |
- |
- |
9 |
50 |
34 |
35.05 |
26 |
4.0 |
15 |
40.0 |
28.5 |
1.18 |
40 |
6 |
34.0 |
0.5 |
○ |
35.1 |
13.6 |
25.9 |
10 |
50 |
34 |
35.05 |
25 |
3.0 |
20 |
40.0 |
38.0 |
1.18 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
18.2 |
34.6 |
11 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
26.1 |
49.6 |
12 |
50 |
34 |
35.05 |
25 |
1.2 |
50 |
40.0 |
95.1 |
1.18 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
47.0 |
89.4 |
13 |
50 |
34 |
35.05 |
25 |
0.9 |
70 |
40.0 |
133.1 |
1.18 |
40 |
6 |
34.0 |
0.4 |
○ |
- |
- |
- |
14 |
50 |
34 |
35.05 |
25 |
25.0 |
1 |
40.0 |
*4.5 |
1.18 |
40 |
6 |
33.6 |
0.9 |
× |
34.6 |
7.5 |
*14.4 |
15 |
50 |
34 |
35.05 |
40 |
6.0 |
10 |
40.0 |
*19.0 |
1.18 |
40 |
6 |
33.6 |
0.9 |
× |
- |
- |
- |
16 |
50 |
34 |
35.05 |
40 |
4.0 |
15 |
40.0 |
28.5 |
1.18 |
40 |
6 |
34.0 |
0.5 |
○ |
35.1 |
13.5 |
25.7 |
17 |
50 |
34 |
35.05 |
40 |
3.0 |
20 |
40.0 |
38.0 |
1.18 |
40 |
6 |
34.0 |
0.45 |
○ |
35.1 |
18.0 |
34.2 |
18 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.45 |
○ |
35.1 |
27.9 |
53.1 |
19 |
50 |
34 |
35.05 |
40 |
1.2 |
50 |
40.0 |
95.1 |
1.18 |
40 |
6 |
34.0 |
0.45 |
○ |
35.1 |
48.0 |
91.3 |
20 |
50 |
34 |
35.05 |
40 |
0.9 |
70 |
40.0 |
133.1 |
1.18 |
40 |
6 |
34.0 |
0.45 |
○ |
- |
- |
- |
21 |
50 |
34 |
35.05 |
40 |
40.0 |
1 |
40.0 |
*2.7 |
1.18 |
40 |
6 |
33.6 |
1.1 |
× |
34.6 |
4.5 |
*8.7 |
22 |
50 |
34 |
35.05 |
25 |
6.0 |
10 |
40.0 |
*19.0 |
1.18 |
40 |
4 |
33.6 |
0.9 |
× |
- |
- |
- |
23 |
50 |
34 |
35.05 |
25 |
4.0 |
15 |
40.0 |
28.5 |
1.18 |
40 |
4 |
34.0 |
0.46 |
○ |
35.1 |
13.0 |
24.7 |
24 |
50 |
34 |
35.05 |
25 |
3.0 |
20 |
40.0 |
38.0 |
1.18 |
40 |
4 |
34.0 |
0.46 |
○ |
35.1 |
17.9 |
34.0 |
25 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
4 |
34.0 |
0.46 |
○ |
35.1 |
26.0 |
49.5 |
26 |
50 |
34 |
35.05 |
25 |
1.2 |
50 |
40.0 |
95.1 |
1.18 |
40 |
4 |
34.0 |
0.4 |
○ |
35.1 |
46.2 |
87.9 |
27 |
50 |
34 |
36.05 |
25 |
0.9 |
70 |
40.0 |
133.1 |
1.18 |
40 |
4 |
34.0 |
0.4 |
○ |
- |
- |
- |
28 |
50 |
34 |
35.05 |
25 |
25.0 |
1 |
40.0 |
*4.5 |
1.18 |
40 |
4 |
33.5 |
1 |
× |
34.5 |
7.0 |
*13.5 |
29 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
8.0 |
57.1 |
*0.24 |
40 |
6 |
34.0 |
0.8 |
× |
- |
- |
- |
30 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
15.0 |
57.1 |
0.44 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
26.9 |
51.2 |
31 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
20.0 |
57.1 |
0.59 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
26.2 |
49.8 |
32 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
26.1 |
49.6 |
33 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
60.0 |
57.1 |
1.76 |
40 |
6 |
34.0 |
0.26 |
○ |
35.1 |
26.8 |
51.0 |
34 |
50 |
34 |
35.05 |
10 |
2.0 |
30 |
80.0 |
57.1 |
2.35 |
40 |
6 |
34.0 |
0.2 |
○ |
- |
- |
- |
35 |
50 |
34 |
35.05 |
10 |
10.0 |
3 |
80.0 |
*11.4 |
2.35 |
40 |
6 |
33.6 |
0.9 |
× |
34.6 |
9.8 |
*18.9 |
36 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
8.0 |
57.1 |
*0.24 |
40 |
6 |
34.0 |
1 |
× |
- |
- |
- |
37 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
15.0 |
57.1 |
0.44 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
26.5 |
50.4 |
38 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
20.0 |
57.1 |
0.59 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
26.5 |
50.4 |
39 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
26.8 |
51.0 |
40 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
60.0 |
57.1 |
1.76 |
40 |
6 |
34.0 |
0.3 |
○ |
35.1 |
26.0 |
49.5 |
41 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
80.0 |
57.1 |
2.35 |
40 |
6 |
34.0 |
0.3 |
○ |
- |
- |
- |
42 |
50 |
34 |
35.05 |
25 |
25.0 |
1 |
80.0 |
*4.5 |
2.35 |
40 |
6 |
33.5 |
1.1 |
× |
34.5 |
6.9 |
*13.3 |
43 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
8.0 |
57.1 |
*0.24 |
40 |
6 |
34.0 |
1 |
× |
- |
- |
- |
44 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
15.0 |
57.1 |
0.44 |
40 |
6 |
34.0 |
0.45 |
○ |
35.1 |
26.0 |
49.5 |
45 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
20.0 |
57.1 |
0.59 |
40 |
6 |
34.0 |
0.45 |
○ |
35.1 |
26.1 |
49.6 |
46 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
40.0 |
57.1 |
1.18 |
40 |
6 |
34.0 |
0.46 |
○ |
35.1 |
26.6 |
50.6 |
47 |
50 |
34 |
35.05 |
40 |
2.0 |
30 |
60.0 |
57.1 |
1.76 |
40 |
6 |
34.0 |
0.4 |
○ |
35.1 |
26.7 |
50.8 |
48 |
50 |
34 |
36.06 |
40 |
2.0 |
30 |
80.0 |
57.1 |
2.35 |
40 |
6 |
34.0 |
0.4 |
○ |
- |
- |
- |
49 |
50 |
34 |
35.05 |
40 |
40.0 |
1 |
80.0 |
*2.7 |
2.35 |
40 |
6 |
33.5 |
1 |
× |
34.5 |
4.1 |
*7.9 |
50 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
8.0 |
57.1 |
*0.24 |
40 |
4 |
34.0 |
0.9 |
× |
- |
- |
- |
51 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
15.0 |
57.1 |
0.44 |
40 |
4 |
34.0 |
0.4 |
○ |
35.1 |
25.9 |
49.3 |
52 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
20.0 |
57.1 |
0.59 |
40 |
4 |
34.0 |
0.4 |
○ |
35.1 |
26.1 |
49.6 |
53 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
40.0 |
67.1 |
1.18 |
40 |
4 |
34.0 |
0.4 |
○ |
35.1 |
26.0 |
49.5 |
54 |
50 |
34 |
35.05 |
25 |
2.0 |
30 |
60.0 |
57.1 |
1.76 |
40 |
4 |
34.0 |
0.4 |
○ |
35.1 |
26.1 |
49.6 |
55 |
50 |
34 |
35.06 |
25 |
2.0 |
30 |
80.0 |
57.1 |
2.35 |
40 |
4 |
34.0 |
0.4 |
○ |
- |
- |
- |
56 |
50 |
34 |
35.05 |
25 |
25.0 |
1 |
80.0 |
*4.5 |
2.35 |
40 |
4 |
33.6 |
1 |
× |
34.5 |
6.8 |
*13.1 |
* outside the geometrical range of the invention |
Method of Examination
[0053] As shown in Fig. 9, conventional dies each having a fixed die half angle R1 were
used in tests Nos. 7, 14, 21, 28, 35, 42, 49, and 56. In Fig. 9, D3=D2/0.97, D2/0.97
holds for D3.
[0054] In the tests other than the tests listed above, dies each having two different die
half angles R1 and R2 as shown in Fig. 5 were used. In each of the tests, the die
half angle R1 was larger than the die half angle R2 (R1>R2).
[0055] Table 1 shows the diameters D1 to D3, die half angles R1 and R2, distances LR and
bearing portion lengths LB of the dies used in the tests. Based on the sizes of the
dies in the tests, F1 and F2 in Equations (5) and (6) were calculated. The calculated
F1 and F2 are given in Table 1.
[0056] With reference to Table 1, the dies used in tests Nos. 2 to 5, Nos. 9 to 12, Nos.
16 to 19, Nos. 23 to 26, Nos. 30 to 34, Nos. 37 to 41, Nos. 44 to 48, and Nos. 51
to 55 all fell within the geometrical range of the invention.
[0057] Meanwhile, regarding each of the dies used in tests Nos. 1, 7, 8, 14, 15, 21, 22,
28, 35, 42, 49, and 56, the value F1 did not satisfy Equation (2). More specifically,
the value F1 was less than 20 for any of the dies.
[0058] Regarding the dies used in tests Nos. 29, 36, 43, and 50, the value F2 did not satisfy
Equation (3). More specifically, the value F2 was less than 0.3. The metal pipe as
a hollow shell was a carbon steel pipe that had an outside diameter DA and a thickness
given in Table 1 and a length of 500 mm.
[0059] The metal pipes in the tests were subjected to an extrusion process and manufactured
into stepped metal pipes. More specifically, the lower end of the metal pipes were
each pushed through a die to protrude a length of 330 mm from the lower end of the
die, and then the pipes were pushed back in the direction opposite to the direction
in which the metal pipes were extruded.
[0060] After the extrusion process, the reduced outside diameter DB of the hollow cylindrical
portion of the stepped metal pipe was measured using a calipers. The bending of the
stepped metal pipe was examined. As shown in Fig. 10, the end of the second hollow
cylindrical portion of the stepped metal pipe was fixed by a lathe 60. The lathe 60
rotates the stepped metal pipe once in the circumferential direction and the bending
amount S of the stepped metal pipe was measured by a dial gauge 61 provided on the
surface 350 mm apart from the end fixed to the lathe 60. When the bending amount S
was not more than 0.5 mm, the pipe was acceptable (indicated by "○" in Table 1), and
when the bending amount S was more than 0.5, the pipe was unacceptable (indicated
by "×" in Table 1).
Results of Examination
[0061] With reference to Table 1, the bending amounts S of the stepped metal pipes obtained
in tests Nos. 2 to 6, Nos. 9 to 13, Nos. 16 to 20, Nos. 23 to 27, Nos. 30 to 34, Nos.
37 to 41, Nos. 44 to 48, and Nos. 51 to 55 were not more than 0.5 mm.
[0062] Meanwhile, the bending amounts S of the stepped metal pipes obtained in tests Nos.
1, 7, 8, 14, 15, 21, 22, 28, 35, 42, 49, and 56 were more than 0.5 mm. The outside
diameters DB of the stepped metal pipes obtained in these tests were smaller than
the diameter D2 (= 34.0 mm) of the die. It is considered that since the length LR
of each of the dies used in these tests was short, undershooting deformation occurred
at the bearing portion, and the bending amounts S exceeded 0.5 mm accordingly.
[0063] The outside diameters DB of the stepped metal pipes in tests Nos. 29, 36, 43, and
50 were each 34.0 mm, but the bending amounts S of these pipes were more than 0.5
mm. It is considered that the bearing portion distances LB of the dies were short
and therefore the bending was caused even though there was no undershooting deformation.
[0064] Note that the thicknesses of the metal pipes had no influence on the bending amounts.
Results of Examination of Geometries of Stepped Pipes
[0065] The geometries of the stepped metal pipes manufactured in tests Nos. 7, 14, 21, 28,
35, 42, 49, and 56 by the extrusion process using the conventional dies were compared
to the geometries of the stepped metal pipes manufactured in tests Nos. 2 to 5, Nos.
9 to 12, Nos. 16 to 19, Nos. 23 to 26, Nos. 30 to 33, Nos. 37 to 40, Nos. 44 to 47,
and Nos. 51 to 54 by the extrusion process using the dies within the geometrical range
of the invention. The measurement results of the outside diameters DC and distances
LE are given in Table 1. In Table 1, "Exp. (4)" indicates the value of LE/((DC-DB)/2).
[0066] Fig. 11 shows by way of examples the measurement results of the outside diameter
of the stepped metal pipe in test No. 14 using a conventional die and the outside
diameter of the stepped metal pipe in test No. 11 using a die within the geometrical
range of the invention in various locations in the axial direction. Among the axial
locations, those on the side of the second hollow cylindrical portion are positive
locations, and those on the side of the first hollow cylindrical portion are negative
locations with respect to the boundary between the taper portion and the second hollow
cylindrical portion of the stepped metal pipe as a reference point ("0" on the abscissa
in Fig. 11). Note that the outside diameters were measured using a calipers. As shown
in Fig. 11, the stepped metal pipes in tests No. 14 and No. 11 had considerably different
geometries. More specifically, the geometry of the stepped metal pipe in test No.
11 satisfied Equation (4) but that of the stepped metal pipe in test No. 14 did not.
Similarly, the geometries of the stepped metal pipes in tests Nos. 2 to 5, Nos. 9
to 12, Nos. 16 to 19, Nos. 23 to 26, Nos. 30 to 33, Nos. 37 to 40, Nos. 44 to 47,
and Nos. 51 to 54 satisfied Equation (4), but those of the stepped metal pipes in
tests Nos. 7, 21, 28, 35, 42, 49, and 56 did not.
[0067] The embodiment of the present invention has been shown and described simply by way
of illustrating the invention. Therefore, the invention is not limited to the embodiment
described above and various changes and modifications may be made therein without
departing from the scope of the invention.
[0068] The die according to the invention can widely be adopted for an extrusion process
to reduce the diameter of a hollow shell, and more specifically it has applicability
in an extrusion process to reduce the diameter of a metal pipe or tube as a hollow
shell.
1. Gesenk mit einer Durchgangsbohrung (31) zur Verwendung bei einem Strangpressprozess,
um den Durchmesser eines Metallrohrs oder einer Metallröhre zu verringern,
wobei die Durchgangsbohrung (31) von der Eintrittsseite des Gesenks eine Innenfläche
mit einem Glockenabschnitt (311), einem Annäherungsabschnitt (312) und einem Lagerabschnitt
(313), die in durchgehender Weise ausgebildet sind, aufweist, wobei
der Durchmesser der Durchgangsbohrung (31) an dem Glockenabschnitt (311) allmählich
von der Eintrittsseite des Glockenabschnitts zu der Austrittsseite des Glockenabschnitts
abnimmt,
der Durchmesser der Durchgangsbohrung (31) an dem Annäherungsabschnitt (312) an der
Eintrittsseite des Annäherungsabschnitts D1 beträgt und an der Austrittsseite des
Annäherungsabschnitts D2 beträgt und von der Eintrittsseite des Annäherungsabschnitts
zur Austrittsseite des Annäherungsabschnitts allmählich abnimmt, um Gleichung (1)
zu erfüllen:
der Gesenk-Halbwinkel einer Innenfläche, bei der der Durchmesser D3 D2/0,97 beträgt,
nicht kleiner als der Gesenk-Halbwinkel einer Innenfläche näher zur Austrittsseite
des Annäherungsabschnitts (312) als der Innenfläche ist, bei der der Durchmesser D3
ist, die axiale Länge LR von der Innenfläche, bei der der Durchmesser D3 ist, zur
Innenfläche, bei der der Durchmesser D2 ist, Gleichung (2) erfüllt:
der Durchmesser der Durchgangsbohrung (31) in dem Lagerabschnitt (313) bei D2 festgelegt
ist und die Länge LB ist und Gleichung (3) erfüllt:
2. Verfahren zum Herstellen eines abgestuften Metallrohrs oder einer abgestuften Metallröhre
(11), welches umfasst:
Schieben eines Metallrohrs oder einer Metallröhre (10) in einer axialen Richtung in
ein Gesenk, wobei das Gesenk eine Durchgangsbohrung (31) zur Verwendung in einem Strangpressprozess
aufweist, um den Durchmesser eines Metallrohrs oder einer Metallröhre zu verringern,
wobei die Durchgangsbohrung (31) von der Eintrittsseite eine Innenfläche mit einem
Glockenabschnitt (311), einem Annäherungsabschnitt (312) und einem Lagerabschnitt
(313), die in durchgehender Weise ausgebildet sind, aufweist, wobei
der Durchmesser der Durchgangsbohrung (31) an dem Glockenabschnitt (311) allmählich
von der Eintrittsseite des Glockenabschnitts zu der Austrittsseite des Glockenabschnitts
der Bohrung abnimmt,
der Durchmesser der Durchgangsbohrung (31) an dem Annäherungsabschnitt (312) an der
Eintrittsseite des Annäherungsabschnitts D1 beträgt und an der Austrittsseite des
Annäherungsabschnitts D2 beträgt und von der Eintrittsseite des Annäherungsabschnitts
zur Austrittsseite des Annäherungsabschnitts allmählich abnimmt, um Gleichung (1)
zu erfüllen:
der Gesenk-Halbwinkel einer Innenfläche, bei der der Durchmesser D3 D2/0,97 beträgt,
nicht kleiner als der Gesenk-Halbwinkel einer Innenfläche näher zur Austrittsseite
des Annäherungsabschnitts als der Innenfläche ist, bei der der Durchmesser D3 ist,
die axiale Länge LR von der Innenfläche, bei der der Durchmesser D3 ist, zur Innenfläche,
bei der der Durchmesser D2 ist, Gleichung (2) erfüllt:
der Durchmesser der Durchgangsbohrung (31) in dem Lagerabschnitt (313) bei D2 festgelegt
ist und die Länge LB ist und Gleichung (3) erfüllt:
wobei das Verfahren umfasst:
Strangpressen eines Endes des geschobenen Metallrohrs oder der geschobenen Metallröhre
(10), um eine vorgeschriebene Länge von der Austrittsseite des Gesenks vorragen zu
lassen, wodurch das Metallrohr oder die Metallröhre (10) zu einem abgestuften Metallrohr
oder einer abgestuften Metallröhre (10) gemacht wird; und
Beenden des Strangpressens und Zurückschieben des abgestuften Metallrohrs oder der
abgestuften Metallröhre (11) in die Richtung entgegen der Richtung des Schiebens des
Metallrohrs oder der Metallröhre (10).
3. Verfahren zum Herstellen eines abgestuften Metallrohrs oder einer abgestuften Metallröhre
nach Anspruch 2, wobei das Metallrohr oder die Metallröhre durch ein Mannesmann-Verfahren
hergestellt wird.
4. Durch das Verfahren nach Anspruch 2 oder 3 hergestelltes abgestuftes Metallrohr oder
abgestufte Metallröhre (11), das/die einen ersten hohlen zylindrischen Abschnitt (101),
einen verjüngten Abschnitt (102) und einen zweiten hohlen zylindrischen Abschnitt
(103) umfasst, die in durchgehender Weise ausgebildet sind, wobei der Außendurchmesser
des ersten hohlen zylindrischen Abschnitts (101) DA ist,
der Außendurchmesser des zweiten hohlen zylindrischen Abschnitts (103) DB ist, der
kleiner als der DA ist,
der Außendurchmesser des verjüngten Abschnitts (102) allmählich von dem ersten hohlen
zylindrischen Abschnitt (101) zu dem zweiten hohlen zylindrischen Abschnitt (103)
abnimmt, wenn der Wert des Außendurchmessers von DA zu DB abnimmt, und der axiale
Abstand LE von der Fläche, bei der der Außendurchmesser DC DB/0,97 ist, zu der Fläche,
bei der der Außendurchmesser DB ist, Gleichung (4) erfüllt: